Automated drywall painting system and method

ABSTRACT

An automated painting system that includes a robotic arm and a painting end effector coupled at a distal end of the robotic arm, with the painting end effector configured to apply paint to a target surface. The painting system can also include a computing device executing a computational planner that: generates instructions for driving the painting end effector and robotic arm to perform at least one painting task that includes applying paint, via the painting the end effector, to a plurality of drywall pieces, the generating based at least in part on obtained target surface data; and drives the end effector and robotic arm to perform the at least one painting task.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.15/942,087, filed Mar. 30, 2018, which is a non-provisional of, andclaims the benefit of U.S. Provisional Application No. 62/480,172, filedMar. 31, 2017, which applications are hereby incorporated herein byreference in their entirety and for all purposes.

This application is also related to U.S. Non-provisional applicationsfiled contemporaneously herewith having attorney Docket Numbers0111061-001US0, 0111061-002US0, 0111061-003U50, 0111061-004U50,0111061-006U50, 0111061-007U50, having respective application Ser. Nos.15/942,158, 15/942,193, 15/941,886, 15/942,318, 15/942,286, and15/941,974 and respectively entitled “AUTOMATED DRYWALL PLANNING SYSTEMAND METHOD,” “AUTOMATED DRYWALL CUTTING AND HANGING SYSTEM AND METHOD,”“AUTOMATED DRYWALL MUDDING SYSTEM AND METHOD,” “AUTOMATED DRYWALLSANDING SYSTEM AND METHOD,” “AUTOMATED DRYWALLING SYSTEM AND METHOD,”and “AUTOMATED INSULATION APPLICATION SYSTEM AND METHOD.” Theseapplications are hereby incorporated herein by reference in theirentirety and for all purposes.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exemplary perspective drawing illustrating an embodiment ofan automated drywall installation system.

FIG. 2 is an exemplary perspective drawing illustrating anotherembodiment of an automated drywalling system.

FIG. 3 is an exemplary block diagram illustrating systems of anautomated drywalling system in accordance with one embodiment.

FIG. 4 is an exemplary block diagram illustrating systems of anautomated drywalling system in accordance with one embodiment, includinga plurality of end effectors configured to couple to an end of a roboticarm.

FIG. 5 illustrates a block diagram of method of installing drywall inaccordance with one embodiment.

FIGS. 6 a, 6 b, 6 c, 6 d and 6 e illustrate an embodiment of a manualmud application profile, where joint compound is applied overconsecutive layers to taper out high points over a wider area and wheresanding is then used to smooth out the final profile.

FIGS. 7 a and 7 b illustrate an embodiment of an automated compoundapplication process where the joint compound is applied in a thick layerusing a sprayer.

FIGS. 8 a, 8 b, 9 a, 9 b illustrate a series of steps in an examplemethod of installing drywall to generate a wall assembly.

FIG. 10 illustrates an embodiment of a drywalling system sanding a wallassembly in accordance with one embodiment.

FIG. 11 illustrates an embodiment of a painting end effector configuredto automatically dispense and apply wallpaper on drywall boards.

FIG. 12 illustrates one embodiment of a painting end effector thatincludes a spray gun that is coupled onto the robotic arm.

FIG. 13 illustrates another embodiment of a painting end effector thatincludes a spray gun that is coupled onto the robotic arm.

FIG. 14 illustrates an example of an in-line nozzle for mixing paint,water, and any additives at an application site.

FIG. 15 illustrates an example embodiment of a painting end effectorthat includes a spray pattern detection mechanism, in which a visionsystem can be used to monitor the pattern of paint spray coming out ofthe nozzle to detect clogs, nozzle wear, low pressure, or other problemswith the spray gun or related system such as paint lines, paint source,or the like.

FIG. 16 illustrates an example embodiment of a painting end effectorthat comprises a vacuum system that includes a vacuum hood disposedaround an end and nozzle of a spray gun to capture overspray.

FIG. 17 illustrates an example embodiment of a painting end effectorthat comprises a spray guard that partially extends about and past theface of the nozzle of the spray gun.

FIG. 18 illustrates an example embodiment of a painting end effectorthat comprises a first blower and a second blower.

FIG. 19 illustrates an example embodiment of a painting end effector,which comprises a nozzle cassette system where a cassette of nozzles isattached to the end of the spray gun.

FIG. 20 illustrates another example embodiment of a painting endeffector that comprises a nozzle rotating system that can be part of aspray gun.

It should be noted that the figures are not drawn to scale and thatelements of similar structures or functions are generally represented bylike reference numerals for illustrative purposes throughout thefigures. It also should be noted that the figures are only intended tofacilitate the description of the preferred embodiments. The figures donot illustrate every aspect of the described embodiments and do notlimit the scope of the present disclosure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following disclosure pertains to an automated drywalling system,which in some embodiments can be used for drywalling, including one ormore of planning a configuration and location of drywall pieces on awall assembly, cutting drywall pieces, hanging drywall pies, performingmud work on hung drywall pieces, performing sanding on mudded drywallpieces and painting sanded drywall pieces.

In one aspect, the present disclosure pertains to an automatic systemsand methods for painting and applying protective coatings onto asubstrate. For example, in one embodiment the system can be used to mix,deliver, apply, and/or dry paint on drywall boards. In anotherembodiment the system can used to apply wallpaper on drywall boards.Although examples herein may discuss paint, the system can also be usedwith any other suitable coatings including varnishes, films, polymercoatings, and the like, which can be applied onto any suitable substrateincluding drywall, wood, metal, polymers, or the like. The system can beconfigured for handling how such a coating is prepared, how it isdelivered onto the substrate and how it is set, cured or dried.

Turning to FIGS. 1 and 2 , examples of an automated drywalling system100 are illustrated, which includes a base unit 120, a robotic arm 140and an end effector 160. The base unit 120 comprises a platform 122 anda cart 124 with a lift 126 disposed between the platform 122 and cart124. The cart 124 can be configured to be disposed on the ground andmove within an XY plane defined by axes X and Y, and the lift 126 can beconfigured to raise the platform 122 up and down along axis Z, which isperpendicular to axes X and Y.

In the examples of FIGS. 1 and 2 , the cart 124 can comprise a pluralityof wheels 128, which can be used to move the cart 124 and drywallingsystem 100 on the ground in the XY plane. Such movement can be motorizedor non-motorized. For example, in some embodiments, the drywallingsystem 100 can be configured for automated movement of the cart 124,motorized movement based on input from a user and/or non-motorizedmovement based on physical movement by a user. Additionally, while anexample having wheels 128 is shown in some examples herein, it should beclear that the cart 124 can be configured for motorized and/ornon-motorized movement via any suitable structures, systems, or thelike.

In the examples of FIGS. 1 and 2 , the lift 126 is shown comprising ascissor lift that can raise and lower the platform 122 relative to thecart 124 along axis Z. Such movement can be motorized or can benon-motorized. For example, in some embodiments, the drywalling system100 can be configured for automated movement of the lift 126, motorizedmovement of the lift 126 based on input from a user and/or non-motorizedmovement based on physical operation of the lift 126 by a user.Additionally, while an example of a scissor lift is shown herein, itshould be clear that any suitable lift system can comprise the lift 126without limitation.

The platform 122 can comprise a hub 130, which can couple with therobotic arm 140 at a base end 142 of the robotic arm 140. The hub 130can comprise an input interface 132 that allows for various systems tocouple with the hub 130, which can allow for resources provided by suchsystems to be provided to the robotic arm 140 and/or the end effector160 coupled at a distal end 144 of the robotic arm 140 as discussed inmore detail herein. For example, a pneumatic source, a power source, avacuum source, a paint source, a mud or joint compound source, or thelike can be coupled to the hub 130. FIG. 1 illustrates an example havingan air compressor 134 and a vacuum source 136 coupled to the hub 130.FIG. 2 illustrates an example having an air compressor 134 coupled tothe hub 130, which can be used to power pneumatic actuators 146 of therobotic arm 140 and/or provide compressed air to the end effector 160 atthe distal end 144 of the robotic arm 140.

In various embodiments, the robotic arm 140 can comprise any suitablerobotic arm system, which can include pneumatic actuators, electricactuators, and the like. The robotic arm 140 can have any suitablenumber of degrees of freedom. Although the examples of FIGS. 1 and 2illustrate an example having pneumatic actuator units 146 separated byarm couplers 148, this example configuration should not be construed tobe limiting on the wide variety of robotic arms 140 that are within thescope and spirit of the present disclosure.

As discussed in more detail herein, an end effector 160 can be coupledat the distal end 144 of the robotic arm 140. In some examples, theautomated drywalling system 100 can comprise modular and/or multi-useend effectors 160, which can be configured for various drywalling,construction, or other tasks. For example, as discussed herein, endeffectors 160 can be configured for drywall planning, drywall hanging,applying mud or joint compound to hung drywall, sanding mudded drywall,painting, and the like. Although various examples herein relate todrywalling and construction, further embodiments of the drywallingsystem 100 can be configured for any suitable tasks, includingconstruction tasks, manufacturing tasks, gardening tasks, farming tasks,domestic tasks, and the like. Accordingly, the discussions hereinrelated to drywalling and construction should not be construed to belimiting on the wide variety of tasks that the system 100 can beconfigured for.

Turning to FIG. 3 , a block diagram of a drywalling system 100 isillustrated, which includes a base unit 120 coupled to a robotic arm140, which is coupled to an end effector 160. The base unit 120 is showncomprising a control system 322, which is operably coupled to a visionsystem 324, sensors 326, and a movement system 328. The robotic arm 140is shown comprising sensors 346 and a movement system 348, which areoperably coupled to the control system 322. The example end effector 160is shown comprising a vision system 364, sensors 366, a movement system368, and one or more end effector devices 370, which are operablyconnected to the control system 322.

In various embodiments, the connections between the control system 322and respective vision systems 324, 364; respective sensors 326, 346,366; respective movement systems 328, 348, 368; and end effector devices370 can comprise any suitable type of connection including wired and/orwireless connections. For example, such connections can be configuredfor digital and/or analog communication of information betweenrespective elements.

The vision systems 324, 364 can comprise one or more suitable visionsystems including one or more visible spectrum camera, radar, lightdetection and ranging (LIDAR) system, sonar, infrared camera, thermalcamera, stereo cameras, structured light camera, laser scanners, and thelike. The vision systems 324, 364 can comprise the same or differentelements. Additionally, in some embodiments, one or both of the visionsystems 324, 364 can be absent. In some embodiments, the robotic arm 140can comprise a vision system.

The sensors 326, 346, 366 can comprise any suitable sensors in variousembodiments including one or more sensors of humidity, temperature, airflow, laser curtains, proximity sensors, force and torque sensors,pressure sensors, limit switches, rotameter, spring and piston flowmeters, ultrasonic flow meters, turbine meters, paddlewheel meters,variable area meters, positive displacement, vortex meters, pitot tubeor differential pressure meters, magnetic meters, humidity sensors,conductivity sensors, and depth or thickness sensors. The sensors 326,346, 366 can comprise the same or different elements. Additionally, insome embodiments, one or more of the sensors 326, 346, 366 can beabsent.

The movement systems 328, 348, 368 can comprise any suitable movementsystems in various embodiments including one or more of an electricmotor, pneumatic actuators, piezo electric actuator, and the like. Forexample, in some embodiments the movement system 328 of the base unit120 can comprise the lift 126 and motors that drive wheels 128 of thecart 124 (see FIGS. 1 and 2 ). In another example, the movement system348 of the robotic arm 140 can comprise pneumatic actuators 146 asillustrated in the examples of FIGS. 1 and 2 . In various embodiments,the movement system 368 of the end effector 160 can comprise motors orother systems that are configured to move, change the orientation of,rotate, or otherwise configure the end effector 160. In someembodiments, one or more of the movement systems 328, 348, 368 can beabsent.

As discussed herein, the one or more end effector devices 370 cancomprise various suitable devices, including a cutting device, hangingdevice, mudding device, sanding device, painting device, vacuum device,and the like. Other suitable devices can be part of an end effector 160and can be selected based on any desired task that the end effector 160can be used for.

As discussed in more detail herein, the control system 322 can receivedata from the vision systems 324, 364 and/or sensors 326, 346, 366 candrive the movement systems 328, 348, 368 and one or more end effectordevices 370 to perform various tasks including drywall planning, drywallhanging, applying mud or joint compound to hung drywall, sanding muddeddrywall, painting, and the like. Accordingly, the control system 322 candrive the drywalling system 100 to perform various suitable tasks, withsome or all portions of such tasks being automated and performed with orwithout user interaction. The control system can comprise varioussuitable computing systems, including one or more processor and one ormore memory storing instructions that if executed by the one or moreprocessors, provide for the execution of tasks by the automateddrywalling system 100 as discussed in detail herein. Additionally, whilea control system 322 is shown as being part of the base unit 120, infurther embodiments, the control system can be part of the robotic arm140 or end effector 160. Also, further examples can include a pluralityof control systems and/or control sub-systems, which can be suitablydisposed in one or more of the base units 120, robotic arm 140, and/orend effector 160.

Turning to FIG. 4 , an exemplary block diagram illustrating systems ofan automated drywalling system 100 that includes a base unit 120 coupledto a robotic arm 140 and including a plurality of end effectors 160configured to couple to the distal end 144 of the robotic arm 140. Inthis example, the end effectors 160 include a cutting end effector 160C,a hanging end effector 160H, a mudding end effector 160M, a sanding endeffector 160S and a painting end effector 160P.

As shown in FIG. 4 , the base unit 120 can comprise a vacuum source 422,a paint source 426, a mud source 430, a power source 432, and one ormore base unit devices 438. In various embodiments, one or more of thevacuum source 422, paint source 426, mud source 430, and power source432 can couple with a hub 130 (FIGS. 1 and 2 ) and provide resources toan end effector 160 coupled at the distal end 144 of the robotic arm 140and/or to the robotic arm 140. For example, the vacuum source 422 can becoupled with a vacuum tube 424 that extends via the robotic arm 140 toan end 424E, which can couple with an end effector 160 as discussedherein. The paint source 426 can be coupled with a paint tube 432 thatextends via the robotic arm 140 to an end 432E, which can couple with anend effector 160 as discussed herein. The mud source 430 can be coupledwith a mud tube 432 that extends via the robotic arm 140 to an end 432E,which can couple with an end effector 160 as discussed herein.

The power source 434 can be coupled with a power line 436 that extendsvia the robotic arm 140 to an end 436E, which can couple with an endeffector 160 as discussed herein. Additionally, the power source 434 canprovide power to arm devices 442 of the robotic arm 140 (e.g., sensors346 and movement system 348) and to base unit devices 438 of the baseunit 120 (e.g., control system 322, vision system 324, sensors 326 andmovement system 328). In various embodiments, the power source cancomprise one or more batteries and/or can be configured to plug intowall receptacles at a work site. For example, a power cord can becoupled to the power source 438, which allow the drywalling system 100to be powered by local power at a worksite via a wall receptacle,generator, external batteries, or the like. However, in someembodiments, the automated drywalling system 100 can be completelyself-powered and can be configured to operate without external powersources at a worksite. In further embodiments, the robotic arm 140and/or end effectors 160 can comprise a separate power source that canbe separate from the power source 438 of the base unit.

In various embodiments, the automated drywalling system 100 can beconfigured to perform a plurality of tasks related to installing andfinishing drywall in construction. In such embodiments, it can bedesirable to have a base unit 120 and robotic arm 140 that can couplewith and operate a plurality of different end effectors 160 to performone or more tasks or portions of tasks related to drywalling. Forexample, the cutting end effector 160C, hanging end effector 160H,mudding end effector 160M, sanding end effector 160S and painting endeffector 160P can be selectively coupled with the robotic arm 140 at thedistal end 144 to perform respective tasks or portions of tasks relatedto drywalling.

For example, the cutting end effector 160C can be coupled at the distalend 144 of the robotic arm 140 and coupled with the power line 436 topower cutting devices 462 of the cutting end effector 160C. The cuttingend effector 160C can be controlled by the automated drywalling system100 to cut drywall or perform other cutting operations. In someexamples, the cutting end effector 160C can comprise a cutting vacuumthat is coupled to vacuum source 422 via the vacuum line 424 to ingestdebris generated by cutting done by the cutting end effector 160C.

The hanging end effector 160H can alternatively be coupled at the distalend 144 of the robotic arm 140 and coupled with the power line 436 topower hanging devices 464 of the hanging end effector 160H. The hangingend effector 160H can be controlled by the automated drywalling system100 to hang drywall, assist with drywall hanging, or the like.

The mudding end effector 160M can alternatively be coupled at the distalend 144 of the robotic arm 140 and coupled with the power line 436 topower mudding devices 466 and/or mudding applicators 468 of the muddingend effector 160M. The mudding end effector 160M can be controlled bythe automated drywalling system 100 to perform “mudding” or “mud work”associated with drywalling, including application of joint compound(also known as “mud”) to joints between pieces of hung drywall, and thelike. Joint compound as discussed herein can encompass pre-mixed,topping, taping, multi-use, all-purpose, and setting type compounds.Additionally, the mudding end effector can also be configured to applyjoint tape, or the like. Additionally, the mudding end effector 160M cancomprise a mudding vacuum 469 that is coupled to vacuum source 422 viathe vacuum line 424 to ingest excess joint compound or mud generated bythe mudding end effector 160M.

The sanding end effector 160S can alternatively be coupled at the distalend 144 of the robotic arm 140 and coupled with the power line 436 topower sanding devices 464 of the sanding end effector 160S. The sandingend effector 160S can be controlled by the automated drywalling system100 to sand mudded drywall, and the like. Additionally, the sanding endeffector 160S can comprise a sanding vacuum 472 that is coupled tovacuum source 422 via the vacuum line 424 to ingest debris generated bysanding done by the sanding end effector 160S.

The painting end effector 160P can alternatively be coupled at thedistal end 144 of the robotic arm 140 and coupled with the power line436 to power a paint sprayer 474 and/or painting devices 476 of thepainting end effector 160P. The painting end effector 160P can becontrolled by the automated drywalling system 100 to paint drywall orother surfaces. Additionally, the painting end effector 160P cancomprise a painting vacuum 472 that is coupled to vacuum source 422 viathe vacuum line 424 to ingest excess paint spray generated by paintingdone by the painting end effector 160P.

Although the example automated drywalling system 100 of FIG. 4 isillustrated having five modular end effectors 160, other embodiments caninclude any suitable plurality of modular end effectors 160, with suchend effectors 160 having any suitable configuration, and being for anysuitable task or purpose. In further examples, the automated drywallingsystem 100 can comprise a single end effector 160, which can bepermanently or removably coupled to the robotic arm 140. Additionally,in some examples a given end effector 160 can be configured to perform aplurality of tasks. For example, in one embodiment, an end effector 160can be configured for mud work, sanding and painting. Accordingly, theexample of FIG. 4 should not be construed to be limiting on the widevariety of other embodiments that are within the scope and spirit of thepresent disclosure.

Turning to FIG. 5 , a method 500 of drywalling is illustrated, which canbe performed in whole or in part by an automated drywalling system 100as discussed herein. The example method 500 or portions thereof can beperformed automatically by the automated drywalling system 100 with orwithout user interaction.

The method 500 begins at 510, where a configuration and location ofdrywall pieces is planned. For example, in some embodiments, theautomated drywalling system 100 can be configured for automated scanningand mapping of a worksite (e.g., framing elements of a house orbuilding) and automated planning of the shapes and sizes of drywall tobe disposed at the worksite to generate walls, ceilings, and the like.Such scanning and mapping can include use of vision systems 324, 364(FIG. 3 ) and the like. Planning of shapes and sizes of drywall can bebased at least in part on the scanning and mapping and can be performedby a computing device 100 of the automated drywalling system 100 orother suitable device which can be proximate or remote from theautomated drywalling system 100. In some embodiments, such planning canbe based at least in part on building plans or maps that were notgenerated by the automated drywalling system 100.

The method 500 continues to 520, where drywall pieces are cut. Suchcutting can be based at least in part on the scanning, mapping andplanning discussed above. Additionally, such cutting can be performed bythe automated drywalling system 100 at a worksite (e.g., via a cuttingend effector 160C) or can be performed by a system remote from theworksite and generated drywall pieces can be delivered to the worksite.

At 530, generated pieces of drywall can be hung at the worksite,including hanging on studs, beams, posts, wall plates, lintels, joists,and the like, to define walls, ceilings and the like. Screws, nails orother suitable fasteners can be used to hang the drywall pieces. In someembodiments, the automated drywalling system 100 can be configured tohang drywall pieces including positioning the drywall pieces andcoupling the drywall pieces in a desired location. In some examples, theautomated drywall system 100 can be configured to assist a user inhanging drywall, including holding the drywall and/or tools in placewhile the user fixes the drywall pieces in place. In various examples, ahanging end effector 160H can be used for such drywall hanging.

At 540, mud work can be performed on the pieces of hung drywall. Forexample, joint compound (known also as “mud”) can be applied to seams orjoints between adjacent pieces of drywall, over faces of the drywall,and/or can be applied over fasteners such as drywall screws or the like.In various examples, a mudding end effector 160M can be used to performsuch mud work.

At 550, sanding can be performed on the mudded pieces of drywall. Forexample, where wet joint compound is applied to hung drywall pieces, thejoint compound can be allowed to dry and can then be sanded by a sandingend effector 160S of an automated drywall system 100. In variousexamples, sanding can be performed to smooth out joint compound togenerate a planar or otherwise consistent profile on the pieces ofdrywall in preparation for painting. At 560, the sanded drywall piecescan be painted. For example, in various examples, a painting endeffector 160P of an automated drywalling system 100 can be used to paintthe drywall pieces.

Although the method 500 of FIG. 5 relates to hanging and finishingdrywall, it should be clear that other hanging and finishing methods cansimilarly be employed by the automated drywalling system 100, includingmethods related to hanging particle board, plywood, sheet rock,laminate, tile, wall boards, metal sheeting, lath and the like.Similarly the methods can be used with different coatings includingplaster, polymer coatings, cement, stucco, organic coatings, and thelike. Accordingly, the method 500 of FIG. 5 should not be construed tobe limiting.

During mud work, automated drywalling system 100 can apply a layer orprofile of compound that is greater than a thickness that isconventionally manually applied by human workers to allow for a sandingsystem (e.g., a sanding end effector 160S) to sand down the compound toa desired plane. For example, in some examples, manual joint compoundapplication mud can be profiled to taper from high points. The automateddrywalling system 100 can apply a thicker layer than normal enabling asanding system to sand down high points to be level to the adjacentsurfaces.

For example, FIGS. 6 a, 6 b, 6 c, 6 d and 6 e illustrate one example ofa mud application profile for a pair of drywall pieces 610A, 610B thatform a seam 620, where joint compound 630 is applied over consecutivelayers, which can include joint tape 640, to taper out the high pointsof joint compound 630 over a wider area. Sanding can then be used tosmooth out the final profile. The high points of joint compound 630 canbe caused by various features, including the seam 620, feature, raisedstud, defect, or any combination of these. In some embodiments, such amud application can be undesirable for automated application; however,in further embodiments, such a mud application profile can be employedby an automated system such as the automated drywalling system 100.

FIGS. 7 a and 7 b illustrate an example joint compound applicationprocess where the joint compound 630 is applied in a thick layer using asprayer that generates a mud spray 700. Such an application process canbe performed by the automated drywalling system 100 in variousembodiments. The thickness of the joint compound 630 being applied tothe pieces of drywall 610A, 610B defining the seam 620 can allow for asanding system to be used to sand back high points of joint compound 630to a level surface. The high points of joint compound 630 can be causedby the seam 620, feature, raised stud, defect, or any combination ofthese.

Turning to FIGS. 8 a, 8 b, 9 a and 9 b , examples of a wall assembly 800including a plurality of drywall pieces 610A, 610B, 610C, 610D isillustrated. The wall assembly 800 can comprise a header 810 and footer820, with a plurality of studs 830 extending therebetween. As shown inFIG. 8 a , the drywall pieces 610 can be coupled to the studs 830 via aplurality of fasteners 840 (e.g., drywall screws) that extend though thedrywall pieces 610 and into the studs 830. The drywall pieces 610 candefine one or more seams 620, including in the example of FIG. 8 a avertical seam 620V and a horizontal seam 630H. In some embodiments, mudwork can be performed on the seams 620 as shown in FIG. 8 b and leavingportions of the drywall pieces 610 without joint compound 630.Additionally or alternatively, joint compound can be applied to portionsof the drywall pieces 610 in addition to about the seams 620 as shown inFIG. 9 . The wall assembly 800 of FIG. 8 b or 9 a can then be sanded togenerate a smooth profile or other profile as desired and the sandedwall assembly can be coated with paint 930 as shown in FIG. 9 b.

FIG. 10 illustrates one example embodiment of the automated drywallsystem 100, having a painting end effector 160P that is configured togenerate a paint spray. In this example embodiment, the system 100 isshown comprising a robotic arm 140 with a painting end effector 160 withintegrated overspray or fume collection 1005. The robotic arm 140 andend effector 160 are shown mounted on a mobile base 120 with a verticallift 126. The base unit 120 can carry supporting systems for theautomated drywall system 100 as discussed herein.

In one aspect, the present disclosure pertains to automatic systems andmethods for painting and applying protective coatings onto a substrate.For example, in one embodiment the system 100 can be used to mix,deliver, apply, and/or dry paint on drywall boards 610. In anotherembodiment the system 100 can be used to apply wallpaper on drywallboards. Although examples herein may discuss paint, the system 100 canalso be used with any other suitable coatings including varnishes,films, polymer coatings, and the like, which can be applied onto anysuitable substrate including drywall, wood, metal, polymers, or thelike. The system 100 can be configured for handling how such a coatingis prepared, how it is delivered onto the substrate and how it is set,cured or dried.

The system 100 can include one or more vision systems 324, 364 and/orsensors 326, 346, 366 (e.g., humidity, temperature, air flow sensors, orthe like) to establish environmental conditions for a painting. Theautomated drywalling system 100 can utilize data from such environmentalsensors to determine a desired paint composition, set path parameterssuch as feed speed, thickness of coating applied, roller pressures,paint sprayer settings, and the like. Environmental information inconjunction with paint parameters can be used to determine or estimatedrying times for the paint allowing the system 100 to plan when a nextstep should begin. The system 100 can also determine when applied painthas set and dried with one or more of the vision systems 324, 364 and/orsensors 326, 346, 366. For example, in some embodiments, the system 100can make such a determination by identifying the moisture content oftarget surfaces by measuring thermal conductivity of the targetsurfaces; using a thermal imaging camera or thermometer (contact ornon-contact); by detecting differences in colors using a camera, or anycombination of these. Thermal measurements can be used to infer themoisture content of applied paint and/or a substrate on which the painthas been applied by comparing the temperature of the paint to thesurrounding materials. For example, as water or other solvent evaporatesfrom an applied paint mixture, the temperature of the paint can be lowerthan that of the surrounding materials. Models of a paint drying processcan also be used to estimate the time to dry or cure given a set ofstarting conditions and information about the environment. Similarly,paint models in combination with environmental and substrate informationcan be used to estimate the finish quality of the material. One or moreof the vision systems 324, 364 and/or sensors 326, 346, 366 can be usedin conjunction with an HVAC system or heater, air conditioner, fans, orthe like to control the room conditions. For example, sensor readingscan trigger any such environment systems or a combination thereof tomaintain the room at the desired conditions for quality, reduced dryingor setting time, or comfort of the operator. In other words, in someembodiments, the system 100 can communicate with and control variousenvironmental conditioning systems to modify the environmentalconditions to be more conducive to desired painting conditions relatedto preparation, application, drying and/or curing of paint.

The automated drywalling system 100 can comprise a variety of tools thatenable the system 100 to mix paint, deliver paint, apply paint, smoothpaint, dry paint, cure paint, or the like. Such tools can be positionedand controlled using the base unit 120, robotic arm 140, end effector160, positioning stage, gantry or the like. In some embodiments, asingle robotic arm 140 or any suitable plurality of robotic arms 140 canbe used to complete a painting task through coordinated or individualpaths. The one or more robotic arms 140, and/or end effectors 160 can bemoved around the room using the mobile base 120 that can be powered ormoved manually by an operator.

The base unit 120, robotic arm 140, and/or end effector 160 can includeone or more vision systems 324, 364 and/or sensors 326, 346, 366 toprovide for safe operation next to users. Such one or more visionsystems 324, 364 and/or sensors 326, 346, 366 can include, but are notlimited to, laser curtains, proximity sensors, force and torque sensors,pressure sensors, limit switches, a system to track location of the userrelative to the robot or mobile base, speed limiters, vision systems,LIDAR, radar, sonar, or any combination of these. The mobile base 120can include a vertical lift 126 component that can be powered orunpowered. The vertical lift 126 can be used to lift or lower theplatform 122, robotic arm 140, end effector 160, positioning stage,gantry or painting tools. The lift 126 can be instrumented with aposition sensor that can be used to capture and control the height ofthe lift 126.

The automated drywalling system 100 can be controlled using a planningsystem (e.g., a planning program executed by the control system 322 orother suitable device) that takes a variety of inputs (e.g., from visionsystems 324, 364 and/or sensors 326, 346, 366) to determine tool pathsand/or tool parameters for the base unit 120, robotic arm 140, and/orend effector 160 to achieve desired coating characteristics and toperform various painting tasks. In some examples, a step in a method forautomated painting includes creating a map of the target surfaces at aworksite (e.g., of wall assemblies 800 as shown in FIGS. 8 a, 8 b, 9 a,9 b or the like). Such a map or model can be created by importingbuilding information modeling (BIM) and/or 2D, 3D plans into the plannersystem. A map can also be created directly by the system 100 byutilizing one or more of vision systems 324, 364 and/or sensors 326,346, 366 to scan the room. In some embodiments, one or more of thevision systems 324, 364 can include stereo cameras, structured light,cameras, LIDAR, radar, sonar, laser scanners, thermal imaging, or thelike. Uploaded 3D or 2D plans can be combined with field data to createa more accurate map of a room or worksite. Data from different sourcescan be combined using key features and user input. A map can include thelocation of the framing studs, drywall joints, openings, protrusions, aswell as pipes, electrical conduit, ventilation ducts, and any othercomponents installed on the walls or ceilings. These locations can bederived from uploaded plans, a room scan and/or user inputs. Tofacilitate the creation of a map, a user can help identify featuresthrough analysis of images, and/or tagging of the features physically ordigitally. The user can physically tag components using a laser, tags,markers or a combination of these. One or more of the vision systems324, 364 and/or sensors 326, 346, 366 can sense or identify these tagsor track them as the user moves around the room and locates thefeatures. A mapping system or planner system of an automated drywallingsystem 100 can also take as an input a layout of how the drywall boards610 were hung in the room to locate seams 620. This layout can be aninput from the automated drywalling system 100 generated at other stagesof a drywalling project performed by the automated drywalling system100, including drywall planning, drywall cutting, drywall hanging,drywall mudding, drywall sanding, and the like. The location of theframing, type of anchors used and layout of the drywall 610 can provideinformation on the planarity, flatness of the wall, and location of highor low points.

The automated drywalling system 100 can include a computational planner(e.g., a program executed by the control system 322 or other suitabledevice), which can utilize a map uploaded to the system 100 and/or a mapcreated by the mapping system to determine tool paths and/or toolparameters required to achieve a desired paint coating application. Theplanner can create toolpaths off a global map of the room and thenupdate these paths given updated local measurements once the base unit120, robotic arm 140, and/or end effector 160 are in place. The plannercan be informed by data from one or more of the vision systems 324, 364and/or sensors 326, 346, 366 on the flatness of the wall, user inputs,location of seams 620 as specified by a layout planner or a scan of theroom after the substrate was applied, or the like. The planner canproduce toolpaths and/or tool parameters, which can enable the system100 to apply paint, wall paper or other coatings to surfaces. The toolparameters and/or tool paths can also be determined by a desired ordefined finish of the coating. For example, areas that are exposed tochanging, harsh, or bright lights can receive a higher quality finishwith tighter controls on paint thickness, overlaps, textures, wall paperseam location, and the like.

2D or 3D maps created by the system 100 can be registered to thephysical environment utilizing recognizable features such as doors,windows, outlets, corners, or the like. The registration can also bedone using markers, tags, laser outlines, or the like that are placed inthe room or worksite. A projection or visualization system can find suchfeatures or markers and can locate the maps created using these. Thesystem 100 can utilize a user interface to enable a user to help locatethe map or projection relative to the environment and resolve any issuesor discrepancies. The user can utilize a physical marker to signify keyfeatures for the system 100 allowing it to locate the plan relative tothe environment. The system 100 can also use the base unit 120, roboticarm 140, and/or end effector 160 to find target features, markers orsurfaces and locate them relative to its own base which can be locatedusing one or more vision systems 324, 364 and/or sensors 326, 346, 366,which in some examples can include laser range finders, computer vision,LIDAR, radar, sonar, stereo vision, odometry, IMUs, or the like.

The robotic arm 140 can utilize a compliant or force limiting endeffector 160 to enable safe contact with the environment allowing thesystem 100 to accurately locate target surfaces, features or components,accommodate errors in positioning without damaging the substrate or therobotic arm 140 or end effector 160. By utilizing the robotic arm 140and compliant end effector 160 to locate a physical component, thesystem 100 can establish a point, line, or plane and therefore locatethe virtual plan on the environment. Toolpaths can then be updated fromthe virtual plane to the physical plane. Refitting of the paths onto thecontacted surfaces enables the system 100 to deal with errors anddiscrepancies between the modeled and physical environment. These toolsenable quick on-site calibration using global room-wide maps and localmeasurements. Refitting the tool paths can allow for correction oferrors in positioning of the base unit 120, robotic arm 140, and/or endeffector 160. The base unit 120, robotic arm 140, and/or end effector160 can also utilize one or more vision systems 324, 364 (e.g., radar,sonar, thermal imaging, or the like) to establish what is behind thesubstrate, and this information can be used to update a virtual map andensure that no damage is done to any electrical, plumbing orventilation.

The planner of the system 100 can output tool poses or tool paths forthe base unit 120, robotic arm 140, and/or end effector 160, includingjoint commands, target poses and end effector positions, or the like.The system 100 can also output paths for a gantry system or positioningstage which can be used in conjunction with the robotic arm 140, orwithout a robot, to move and position coating tools of an end effector160. The planner can also output paths for the mobile base 120 toposition a gantry, positioning stage, or robotic manipulator 140, tomove a tool to assist the user in the finishing process, or positionvisualization and/or lighting equipment. The mobile base 140 includingthe vertical lift 126 can work in coordination with the user, roboticmanipulator 140, end effector 160, gantry or a combination of these toexecute a painting or coating task. The planner system can control thedifferent components of the platform such as the base unit 120, roboticarm 140, and/or end effector 160, which can allow for coordinatedmovements and forces with the target goal of moving the end effector 160to a desired position under the prescribed forces and moments. Theposition of the mobile base 120 can be used as a rough positioningstage, with the vertical lift 126 setting a height of the roboticmanipulator 140 which can act as a fine positioning stage.

Although various embodiments discussed herein relate to painting, someembodiments can relate to applying wallpaper or other planar material toa substrate. For example, FIG. 11 illustrates an example embodiment of awallpaper applicator end effector 160W, wherein a roll of wallpaper 1110is mounted within a roll body 1120 of the end effector 1130 and fedthrough a blade 1130. The wallpaper end effector 160W can be moved overa target surface and the blade 1130 can press down the wallpaper ontothe surface. In some examples, adhesive can be present of the rolledwallpaper 1100 applied to the wall, or the wallpaper 1110 can be withoutan adhesive and the wallpaper 1110 can be applied over an adhesive thathas been applied to the target surface. In some examples, an adhesivecan be applied with an end effector 160 by spraying. Some examples caninclude a separate end effector 160 having an adhesive spray gun, or anadhesive spray gun can be part of a wallpaper end effector 160W, that isconfigured to apply adhesive in front of the wallpaper 1110 onto asurface that the wallpaper 1110 is being applied to and/or by applyingthe adhesive onto the wallpaper 1110 before the blade 1130. Thewallpaper 1110 can come pre-impregnated with adhesive in some examples.

In various embodiments, the system 100 can utilize various suitable endeffectors 160 to automatically dispense and apply wallpaper 1110 ondrywall boards 610 or other suitable substrate. In one embodiment, thewallpaper 1110 can be fed off a roll onto a wall after being coveredwith adhesive. In another embodiment, the adhesive is delivered ahead ofthe wallpaper 1110 through a roller, sprayer, brush, or the like and thewallpaper 1110 is applied onto the surface using a blade, trowel,roller, or the like. Tracking the position of a wallpaper end effector160W with one or more of the vision systems 324, 364 and/or sensors 326,346, 366 can enable the planner system to create an updated map of theroom with the location of the wallpaper 1110 and the conditions underwhich the wallpaper was applied. The one or more of the vision systems324, 364 and/or sensors 326, 346, 366 can use tags or markers to trackas a user manually applies the wallpaper 1110 on the surfaces and thatinformation can be fed into the planner. The base unit 120, robotic arm140, and/or end effector 160 can be used to control the orientation ofwallpapering tools of the end effector 160 and the force applied on thetarget surface as the wallpaper 1110 is applied, which can ensure thewallpaper 1110 is applied with the required pressure for adhesion.

FIG. 12 illustrates one embodiment 160P2 of a painting end effector 160Pthat includes a spray gun 1210 that is coupled onto the robotic arm 140.A trigger 1220 can be actuated with an actuator 1230 (e.g., a servo,solenoid, pneumatic cylinder, or the like) which can pull on the trigger1220 to open the nozzle 1240 to generate a paint spray 1250.

In another example, FIG. 13 illustrates another embodiment 160P3 of apainting end effector 160P that includes a spray gun 1210 that iscoupled onto the robotic arm 140. An internal trigger (not shown) can beactuated with an actuator (e.g., a servo, solenoid, pneumatic cylinder,or the like) which can open the nozzle 1240 to generate a paint spray1250. In the examples of FIGS. 12 and 13 , paint can be fed to the spraygun 1240 and nozzle 1240 via a paint tube 428, which can feed paint (orother suitable coatings in further embodiments) from a paint source 426disposed at the base unit 120 (See FIG. 4 ).

In various embodiments, a painting end effector 160P is used to deliverpaint or other suitable coating to a target surface. In some examples aspray gun 1210 can comprise an airless spray system or air assistedspray system. A pump can be used to move the paint 930 from the paintsource 426 to the spray gun 1210. The paint 930 can be pumped at highpressures, in some examples, to enable the paint 930 to be sprayed oraerosolized. In some examples, high paint particle speeds can produce asmoother finish, which can be desirable in some examples.

The pressure, flow rate, piping system resistance and the like, can betuned or controlled by the automated drywalling system 100 to change thespeed and amount of paint 930 being delivered to the spray gun 1210 andejected from the nozzle 1240 as a spray 1250. The automated drywallingsystem 100 can use any suitable actuator (e.g., a servo, solenoid, aircylinder, linear actuator, or any combination of these) to open andclose the nozzle 1240 of the spray gun 1210. As shown in the example ofFIG. 12 , a manual spray gun 1210 can be instrumented to use anelectromechanical system 1230 to pull the trigger 1220 allowing thesystem 100 to control the timing of the joint compound delivery as wellas the opening and closing of the nozzle 1240.

As shown in the example of FIG. 13 , an automatic spray gun 1210 canalso be used and controlled by the system 100 directly. The robotic arm140 and end effector 160 and/or base unit 120 can thereby be used tospray paint 930 as a spray 1250 onto surfaces of drywall pieces 610and/or seams 620 defined by one or more drywall pieces 610, which can becovered by joint compound 630 and/or joint tape 640. The painting endeffector 160P can also be used to apply adhesive onto the surface forwallpaper application.

The spray gun 1210 can use a variety of suitable nozzles 1240 includingfan shape, bell shape, or the like. The system 100 can also use atunable spray gun 1210 that can control the shape of the nozzle 1210.The shape of the paint spray 1250 can be controlled in some examples byphysically changing the shape of the nozzle 1210. The shape of the paintspray 1250 can also be controlled using air streams or the like whichcan act on the paint spray 1250.

In some embodiments, a cassette with different nozzles 1240 can beinstalled on the spray gun 1210 allowing the automated drywalling system100 to select a desired nozzle 1240 to control the shape of the spray1250. A fan shape can also be tuned by using a set of sliding mechanismsto set the fan width and opening of the nozzle 1240. The diameter of abell may also be tuned by a sliding cone with expanding orifice size.The robotic arm 140 and/or base unit 120 can also be used to move thenozzle 1240 closer or farther away from a target surface resulting in anarrower or wider fan or bell spray pattern respectively. The system 100can utilize an array or series of nozzles 1240 to spray the paint 930over a larger surface. The nozzles 1240 can be individually controlledand tuned or such nozzles 1240 can be controlled as a unit.

A series of tests can be performed to establish the characteristics of apattern of paint spray 1250 delivered by a nozzle 1240. In oneembodiment, one or more vision system 324, 364 can be used tocharacterize a pattern of paint spray 1250 and provide feedback fortuning parameters including tool parameters related to a nozzle 1240,spray gun 1210, paint source 426, or the like, as discussed herein.Another embodiment can utilize an array of sensors (e.g., piezo sensorsor other force sensors) on a test board which can be used to measure theforce applied by the pattern of paint spray 1250 as it hits the sensors.The force pattern can be used to estimate a profile of the pattern ofpaint spray 1250 as it is hitting the surface. The feedback from thesesensors may be used to tune the profile of one or more spray nozzles1240, spray gun 1210, paint source 426, or the like.

The automated drywalling system 100 can include a mixer, pump and thelike that can deliver mixed paint 930 to the various tools including aspray gun 1210. Such a mixer, pump and the like can be part of a paintsource 426 disposed at the base unit 120 or disposed external to thesystem 100. In embodiments, where paint or other suitable coatings areused, a mixer can utilize sensors to control a mixing ratio of water,slurry, pigments, or dry coating material, and any additives thatenhance structure of the coating material, color the coating material,decrease setting or drying time, or the like. The mixer can control themix ratio by measuring the mass, volume, density, or viscosity of thecomponents or the mixture that defines the paint 930 or other coatingmaterial. The mixing system can utilize pre-mixed paint 930 or can addwater and/or additives as desired to a mixture.

The automated drywalling system 100 can also use a spray gun 1210 thathas been designed to mix the components of the paint 930 at the nozzle1240. For example FIG. 14 illustrates an example of an in-line nozzle1240 for mixing a coating material (e.g. paint 930, joint compound 630,adhesive, or the like) with water, and any additives at the applicationsite. The nozzle 1240 or other cartridge or packet can be detachable insome examples to be cleaned or to be disposable.

Paint lines 428, a nozzle 1240, a pump, or the like, can be instrumentedwith sensors to measure flow rate, pressure and other desirableparameters. Pressure sensors can be used to monitor the pressure along apaint line 428 enabling the detection of changes in the pressure, flowrate, as well as the detection of clogs. In some examples, an orificeplate may be used to measure the flow rate through the paint system incombination with a set of pressure sensors. Other flow rate sensors caninclude, but are not limited to a rotameter, spring and piston flowmeter, ultrasonic flow meter, turbine meter, paddlewheel meter, variablearea meter, positive displacement, vortex meter, pitot tube ordifferential pressure meters, or magnetic meters for conductivecoatings. Detecting a change in flow, pressure in the paint line 428, orreaction force at the end effector 160 (e.g. at a spray gun 1210) can beused to determine that a clog has occurred. The spray gun 1210 canproduce a reaction force when spraying so if that reaction force changesthe system 100 can identify that the paint spray 1250 has changed, whichcan be indicative of a clog or other issue.

A pattern of the paint spray 1250 can also be monitored to detect clogsor wear of the nozzle 1240. For example, FIG. 15 illustrates an exampleembodiment 160P4 of a painting end effector 160P that includes a spraypattern detection mechanism 1505, in which a vision system 364 can beused to monitor the pattern of paint spray 1250 coming out of the nozzle1240 to detect clogs, nozzle wear, low pressure, or other problems withthe spray gun 1210 or related system such as paint lines 428, paintsource 426 or the like.

In some examples, the stream of paint spray 1250 can be monitored or thepattern of paint spray 1250 on a target wall can be monitored. Thestream of paint spray 1250 and/or pattern of paint spray 1250 can bemonitored using vision sensors 364, which can include any suitablevision system, including but not limited to thermal sensors, moisturesensors, capacitance sensors, or the like.

In one embodiment, a camera can be placed next to the stream of paintspray 1250 so that the profile of the paint spray 1250 is captured.Image processing can be used to identify when the shape of the stream ofpaint spray 1250 has changed. In another embodiment, a laser curtain maybe placed across the stream of paint spray 1250, and if the flow isinterrupted along any part of the fan or bell, the laser would completeits path and be detected by a sensor on the other side of the stream ofpaint spray 1250.

A mixer, pump, paint lines 428, and nozzle 1240, and other suitableelements can be fitted with filters which can be used to catch debris orparticles that may clog the nozzle 1240 or paint lines 428. The filterscan be placed an inlet of the pump, outlet and inlet of the mixer,directly before the paint line 428, directly before the nozzle 1240, orany point along or within the painting system. The automated drywallingsystem 100 can monitor the pressure before and after the filters todetect when the filters need to be changed. Flow rate sensors can alsobe used to detect a clogged filter. The automated drywall system 100 canreverse its flow to clear clogs from the paint line 428, nozzle 1240,filters, or other components.

The spray gun 1210 or other painting end effector 160P can also includea vacuum system 478, spray guards, or the like, that can be used tominimize overspray or fumes and reduce the amount of excess joint paint930 in the air. For example, FIG. 16 illustrates an example embodiment160P5 of a painting end effector 160P that comprises a vacuum system 478that includes a vacuum hood 1605 disposed around the end and nozzle 1640of a spray gun 1610 to capture overspray or fumes. The vacuum hood 1605can surround the spray gun 1210 and can include an adjustable vacuumsetting. The vacuum hood 1605 can be coupled to the vacuum line 424,which is connected to the vacuum source 422 to provide a vacuum to thevacuum hood 1605.

FIG. 17 illustrates an example embodiment 160P6 of a painting endeffector 160P that comprises a spray guard 1705 that partially extendsabout and past the face of the nozzle 1260 of the spray gun 1210. Inthis example, the spray guard 1705 is shown being generally triangularand fanning out from where the spray guard is coupled to the endeffector 160M. In some examples, the spray guard 1750 can be selectivelydeployed by the system 100 or a user to prevent overspray onto anundesired surface. The spray guard 1705 can be deployed in varioussuitable ways, including but not limited to, via a servo, pneumaticcylinder, solenoid, or other electromechanical actuator, which canrotate or otherwise deploy the spray guard 1705 into place.

In various embodiments, a painting end effector 160P can comprise one orboth of a vacuum system 478 and spray guard 1705 of various suitableconfigurations. The guard 1705 and/or vacuum system 478 can be deployedwhen the automated drywall system 100 is spraying near another surfaceor a feature. The spray guards 1705 and/or vacuum systems such as avacuum hood 1605 can be retracted using a linear actuator, solenoid, aircylinder, or other suitable electromechanical actuator. In someembodiments, a spray guard 1705 can also be mounted on a rotary stagesuch that the spray guard 1705 can be rotated into place next to thesprayer 1210 by actuating the motor or servo. Accordingly, in someexamples, the position of the spray guard about a circumference of thespray gun 1210 can be selected by the system 100 and/or a user.

In some embodiments, paint (or other coating material) can be applied bythe automated drywalling system 100 via a roller, brush, or the like,which can be part of a painting end effector 160P. The paint or coatingcan be delivered to the end effector 160 (e.g., via paint lines 428 andpaint source 426) or such a paint or coating can be sprayed directlyonto the wall and back-rolled with an end effector 160. The paint can beback-rolled to facilitate blending of subsequent work. The roller orbrush can be disposable or reusable. The end effector 160 can utilizethe surrounding surfaces as datums, and in some examples a roller,wheel, blade, or the like can be pushed in contact with the datumsurface for reference. These contact points can extend away from thepaint application zone to enable the use of datums away from the defector joint. The end effector 160 can control the position of the contactpoints such that the correct or optimal datum surface is used. The forceand pressure on the contact points can also be controlled. Force can bedirectly measured or estimated by monitoring the deflection of themounting structure.

Painting or coating tools can be mounted in series with a structure thatlimits, sets, or controls the amount of force applied on the surface.The structure can limit, set or control only the normal force applied onthe surface by the blades, rollers, trowels or it can also limit, set orcontrol forces applied by the tools along the target surface as well astorques applied. Blades or rollers can be mounted on an air bag, airshock, air cylinder, air bellows, or the like, with a fixed or variablepressure setting. The pressure and the normal area of the pressurevessel can set the amount of forces applied by the tool on the surface.A blade or roller can also be mounted on a spring, tunable spring, orshock in order to set, limit or control the forces applied on thesurface. The forces can also be set, limited, or controlled using apressure-controlled hydraulic system including a cylinder, bellows,reservoir, or the like. In one embodiment, a short-stroke low-mass endeffector linear actuator mechanism can be used for fast tracking ofsurface contours and constant normal force. In embodiments with morethan one blade or roller, tools can be mounted on a singleforce-limiting structure or each head or multiple tools can be mountedon separate structures. Mounting the tools or group of tools on separatestructures can allow for the applied forces and moments to be set,limited, or controlled separately.

Painting or coating tools can include sensors 366 and/or a vision system364 to ensure the desired orientation of the blades or rollers relativeto the wall. For example, one application includes ensuring planarity ofthe tool to the wall; however, the mechanism may also set the blade orroller to a specific target angle relative to the surface. The planaritymay be established by utilizing the vision system 364 to detect theplane of the surface and then match the tool position using the degreesof freedom of the system 100. The planarity may also be established byutilizing one or more sensors 366 at the end effector 160 (e.g., a setof proximity, range, or contact sensors to establish the position of atool head relative to a wall). Blade or roller orientation can becontrolled directly by setting the joint angles of the robotic arm 140,by a powered gimbal or joint at the end effector 160, and/or by apassive gimbal that allows the tool to tip and tilt relative to the endof the robotic arm 140. A passive gimbal can enable the contact tool tofollow the plane of a target surface despite errors in the position ofthe system 100.

In another embodiment, the position of the contact may be controlledthrough the active gimbal using feedback from one or more of sensors366, 346, 326 and/or vision systems 364, 324 that can establish therelative orientation between blades or rollers and the surface. Poweredor passive gimbals or end effector degrees of freedom can be encoded(e.g., via sensors 366) such that the orientation of the tool and/or endeffector 160 is known to the system 100.

A painting end effector 160P can also utilize outriggers such as rollersto use adjacent surfaces or raised edges as datums to guide theapplication of paint 930 (or other suitable coating) and achieveaccurate corners. These rollers may be instrumented with sensors 366and/or a vision system 364 to measure or determine force, contact,proximity, or the like. Additionally, or alternatively, such rollers canpassively make contact while the drywalling system 100 utilizes itssensors 366, 346, 326 (e.g., force and torque sensing) and/or visionsystems 364, 324 to maintain a pressure or force against the datumsurface. The information obtained or determined about tool orientationrelative to the portions of the end effector 160, robotic arm 140 and/orbase unit 120 can be used to alter the toolpath, tool parameters and/orother system configurations to ensure the coating automation system cancarry out the process without running into limitations of the hardware.

In both passive and active embodiments, the angular position of a gimbalor other portion of an end effector 160 can be recorded (e.g., viasensors 366 or vision system 364) to locate and establish the plane ofthe target surface. The angular position of the gimbal can be recordedusing elements including, but not limited to encoders on the rotaryaxis, laser range finders, capacitance sensors, IMUs, an external visionsystem, sonar sensors, potentiometers, motor loads, or any combinationof these.

The gimbal system can be tuned to minimize dynamic effects by usingsprings, dampers or a combination thereof. In some embodiments with morethan one blade or roller, all tools may be mounted on a single gimbalstructure or each tool or groups of tools can be mounted on separategimbals. Mounting the blades or rollers on separate gimbals can allowsfor tool surface planes to be set, limited, or controlled separately.Paint application tools can be mounted on a gimbal in series with acompliant system described above that limits, sets, or controls theforce applied on the surface.

In some embodiments, a painting end effector 160P can include elementsincluding, but not limited to, a heater, curing light, blower or acombination of these. For example, FIG. 18 illustrates an exampleembodiment 160P8 of a painting end effector 160P that comprises a firstblower 1805 and a second blower 1810. The first blower can be configuredto apply cool and/or dry air to paint 930 that has been applied to thedrywall board 610 by the painting end effector 160P. The second blower1810 can be configured to apply heat and/or dry air to a surface ofdrywall 610 on which paint 930 will be applied. As shown in FIG. 18 ,the painting end effector 160P can include a paint applicator 1815 thatcan include a tracking knife 1820 that can be used to profile the paint930. In various embodiments, preheating and drying the surface ofdrywall 610 on which paint 930 is being applied can improve the paintapplication process. Cooling and/or drying the applied paint 930 via thefirst blower 1805 can be desirable to speed the drying/curing process ofthe paint 930 and can improve the finish of the paint 930.

In various embodiments, elements including but not limited to a heater,fan, UV light, microwave emitter, or a combination of these elements canalso be part of the automated drywalling system 100 or can be separatefrom the drywalling system 100. These components can be mounted on arobotic arm 140, mobile base 120, end effector 160, positioning stage122, gantry or can be static in the room and separate from the automateddrywalling system 100. A purpose of these components can be to speed upthe curing, drying, or setting time of the paint 930, but can also beused to prepare the surface for the application of paint 930. Anembodiment of the end effector 160 utilizes a heater that leads thepaint application for preheating the surface of drywall 610 on whichpaint 930 will be applied by the painting end effector 160P. The paintapplication point can be followed by a blower which can act over theapplied paint 930. The painting end effector 160P can also utilize twoheaters leading and following the paint application or utilize two fansor a combination of these. The tool parameters or settings on the fan,heaters, or lights may be determined by the planning system (e.g., bythe control system 322) using information from one or more of sensors366, 346, 326 and/or vision systems 364, 324. For example, environmentalsensors (e.g., temperature, humidity, and the like) and a prescribedpaint composition and applied thickness can be used to determine toolparameters for environmental control tools or systems such as heaters,coolers, blowers, or the like. In another example, the painting endeffector 160P can comprise a thermal imaging camera to assess thetemperature of the paint 930 and calculate the moisture content of thepaint 930. The automated drywalling system 100 can also have a humiditysensor, conductivity sensor and depth or thickness sensors such as laserrange finders, sonar, radar, LIDAR, and the like. Toolpaths, toolparameters settings, paint composition, fan, heater, light settings, andthe like can be adjusted in real-time based at least in part on themeasurements, sensing or data obtained from such sensors or visionssystems.

The automated drywalling system 100 can utilize additives to acceleratethe setting time of paint 630 or other coating. An accelerant can bemixed into the paint 930 during preparation, added in at the nozzle1240, applied to a coating of paint 930 after deposition, or anycombination of these. The automated drywalling system 100 can utilizeenvironmental information to decide the amount of accelerant to add andat what point in the process it should be introduced. In other words,data from one or more vision systems 324, 364 and/or sensors 326, 346,366 to automatically modify the parameters of the composition,preparation, and application of paint 930 and/or additives for paint930. In some examples, accelerant may be sprayed onto a coating of paint930 after the paint 930 has been applied onto the target surface.

The automated drywalling system 100 can utilize sensors (e.g., humidityor conductivity sensors) that are mounted on a surface of drywall 610before paint application, which can provide for tracking of the moisturecontent of the surface of drywall 610 and/or paint 930 applied to thesurface of drywall 610. Such sensors can be mounted directly onto thetarget surface, may be embedded in a joint 620, or can be mounted on acoupon that is covered at the beginning of the process with the sameparameters. Such sensors can be connected to a wireless communicationsystem to send signals/data to the automated drywalling system 100.Moisture content and other information collected by such sensors can beused to control or adjust the settings on fans, blowers, heaters, curinglights, an HVAC system, or the like. The drying speed can also be usedto adjust the composition of the paint 930. Monitoring the moisturecontent can allow the system 100 to accurately estimate the time whenthe next drywalling process can begin (e.g., painting, coating, or thelike).

The automated drywalling system 100 can also determine when the paint930 has set and dried by measuring the thermal conductivity of a coveredseam 620 or drywall 610 using a vision system (such as a thermal imagingcamera); using a sensor such as a thermometer (contact or non-contact);or by detecting differences in colors using a vision system (e.g., dueto color changes that occur between wet and dry paint 930). Variousmeasurements can be used to infer the moisture content of paint 930 bycomparing a determined temperature of the paint 930 to the surroundingmaterials such as a sheet of drywall 610. For example, as water or othersolvent evaporates from a mixture of paint 930, the temperature of thepaint 930 can be lower than that of the surrounding materials. Models ofthe paint-drying process can also be used to estimate the time to dry orcure given a set of starting conditions and information about theenvironment. The environmental sensors and/or vision systems can be usedin conjunction with an HVAC system or heater, air conditioner, fans, orthe like to control the room conditions at a worksite. The sensorreadings can automatically trigger any of these systems or a combinationto maintain the room at the desired conditions for quality, reduceddrying time, or comfort of the operator.

The automated drywalling system 100 can also tune the profile of adelivered coating of paint 930 (or other suitable coating) to accountfor overlap of a subsequent stroke of a paint gun 1210 or other paintingtool. For example, paint thickness at the edges can be reduced orfeathered such that the overlap region achieves the final desiredthickness. This approach can also be used to increase overlap errortolerance at transition points between robot workspaces. The automateddrywalling system 100 can utilize the information about the room such aslocation of windows and lighting fixtures to tune the painting toolpathsto achieve the most consistent finish near these features. The automateddrywalling system 100 can optimize the path to minimize overlaps orbreaks in the stroke near the light sources. The system 100 can alsoapply the coating in a criss-cross pattern to create a more eventhickness or better finish. The planner system of the automateddrywalling system 100 can output paths that guide the tool in thiscriss-cross pattern.

The automated drywalling system 100 can be instrumented with one or morevision systems 324, 364 and/or sensors 326, 346, 366 to improveoperation and ensure quality. During painting, coating or wallpaperapplication the automated drywalling system 100 can use sensors 326,346, 366 (e.g., force and torque sensors), which can be mounted directlyon the base unit 120, robotic arm 140, and/or end effector 160, or theforce and torque estimates of robotic joints can be used to apply therequired force during rolling or smoothing. The sensors 326, 346, 366can monitor only force normal to a blade, rollers or the like, ormultiple axes can be monitored including torque measurements andsix-axis sensing. Force sensing can be used to control the force orpressure applied by the tool of an end effector 160. A minimum force orcontact reading can also be used to ensure contact is made with a targetsurface before the paint 930 or other coating material is allowed toflow, with target surface contact force below a certain threshold orloss of contact triggering the stop of material flow. The automateddrywalling system 100 can use force information to operate in forcecontrol, where the motions and speeds of the system 100 are driven toensure a given force is applied in the desired directions. Similarly,force sensing can be used to detect contact with an object, obstacle, orintersecting wall or ceiling. By monitoring the forces and torque on thebase unit 120, robotic arm 140, and/or end effector 160, the system 100can detect that it has made contact with the adjacent wall or ceilingand alter the toolpath accordingly. The measurements can also be used todetect accidental contact and trigger a safety operation such asstopping the system 100 or retracting away from the contact point. Thebase unit 120, robotic arm 140, and/or end effector 160 can also usecontact or proximity sensors to detect that the end effector 160 istouching a target surface, obstacle, object, or worker, as well asdetect the distance to an adjacent surface or contact with that surface.The force, contact, displacement, or proximity sensors can be mounted onoutriggers from the end effector to sense obstacles, objects, oradjacent surfaces ahead of the tool. The system 100 can detect, follow,and use adjacent walls as datums to guide the coating application andachieve accurate corners or to guide the tool during accent painting.For example, in some embodiments, the end effector 160 can comprise aguiding element configured to engage a target surface, adjacent walls,or the like, to allow the end effector 160 to be guided in painting thetarget surface. For example, such a guiding element can include an armextending from the end effector 160, with the arm having a roller at theend of the arm configured to engage the target surface or portion of awall assembly as a painting guide.

The base unit 120, robotic arm 140 and/or end effector 160 can utilizemultiple control strategies to complete various tasks. Position controlcan be used to command the system 100 to follow a trajectory givenspeed, acceleration, and jerk constraints. The system 100 can becontrolled at the joint level by giving commands to the joints toachieve the desired robot state and tool position, or the control can bedone at a higher level allowing a user or program to control endeffector position and orientation. The system 100 can be controlled intask space where the system 100 controls a tool relative to the task.This approach can focus on achieving a desired tool position,orientation, speed, or the like, relative to the target surface ratherthan on each joint reaching its target goal. The system 100 can utilizeforce control to control the force applied to the target surface, anobstacle, adjacent surfaces, objects and so on. The applied force can becontrolled in a single or multiple axes. Hybrid control modes can alsobe used. For example, the system 100 can be commanded to achieve a givenposition as long as a given force is not exceeded.

The one or both of the vision systems 324, 364 can be used to capturewhere and how paint 930 or other coating has been applied. By monitoringthe spray pattern applied on the wall the system 100 can detect clogs,nozzle or blade wear, or other problems. In one example, a thermalcamera can be used to detect the applied paint 930, which can be at adifferent temperature than the target material. The paint's temperaturecan be controlled to facilitate detection. Monitoring the painttemperature can also give information on the moisture content of thepaint 930. The color can change as the paint 930 dries, which can bedetected via vision systems 324, 364. Sensing such as capacitance,radar, resistance, humidity, conductivity, sonar measurements, or anycombination of these can also be used to establish the thickness ofpaint 930. Lights can be mounted on the system 100 or externally toilluminate the surface enabling the detection of coated surfaces, highand low points, tool marks, coating roughness, orange peel, and defectsusing one or both of vision systems 324, 364.

The system 100 can monitor the coverage achieved by the end effector 160and update tool paths and tool parameters to ensure the desired coatingprofile is being applied. For example, the system 100 can dynamicallytune a sprayer fan and/or bell or other parameters of a nozzle 1240until the paint spray pattern matches the desired shape, thickness,size. The system 100 can also move the sprayer 1210 closer or fartheraway from the target surface to change the spray pattern. The system 100can also tune the material flow rate, pressure, spray tool speed, or thelike, to achieve a desired thickness. The toolpaths and/or toolparameters can also be updated to ensure that the correct overlap isbeing achieved.

The system 100 can also utilize a feedback mechanism for communicatingcontact, forces, gimbal displacement information, tool orientation,motor loads, humidity and temperature readings, and/or measurements ofthe applied paint 930, to system 100 (e.g., to the control system 322)for the purpose of real time updating of the tool paths and toolparameters for improving finish of paint 930. The system 100 can usetool position and orientation, captured surface conditions, and modelsto update the robotic toolpaths to ensure that a desired position and/orcontact is maintained during application of paint 930.

The system 100 can also determine areas that need another application ofpaint 930, rework using automated drywalling system 100, or rework to bedone manually by the user. The user can also use a user interface of thesystem 100 to indicate areas that the user has identified as needingrework or need an additional coat. The system 100 can use this inputalong with other information about the previous work to create a newtoolpath. Both user and system feedback can be fed into a machinelearning algorithm to create a better model for coating future surfacesgiven a set of initial conditions.

The automated drywalling system 100 can utilize a user interface toenable the worker to control, program, debug, plan, and setup the system100. The user interface can be used to give the user information aboutall the steps that must be taken to setup the system 100. Each step canbe checked off when complete and the user can request more informationon each step. The workspace of the system 100 can be shown overlaid on acamera feed or projected onto the target surface to help the userposition the end effector 160, robotic arm 140 and/or mobile base unit120. The workspace can be projected using lights or lasers. The system100 can also automatically perform certain steps and the user interfacecan report the progress of each step, as well as give guidance to thesteps the user can follow to perform a task. The user interface can beused to setup the system 100 and run any calibration routines required.The interface can also be used to plan a job including detecting walls,user definitions of path parameters or the path itself, auto generationof the tool path, user input of tool parameters, and automaticallyoptimized tool parameters given a set of user inputs.

The user interface can be a graphical user interface and include a 2D or3D representation of the worksite and workspace. The representation caninclude camera feeds as well as computer models and reconstructionscreated using sensor data. The interface can overlay paths, qualityvisuals, progress, robot models, and the like, over camera or workspacemodels. As the task is completed the path can be highlighted indifferent colors or with different style lines to indicate completion,quality achieved, and problem areas among others.

Any problems, issues, or bugs can be reported in the user interface.Lights on the end effector 160, mobile base 120 and/or robotic arm 140as well as sounds can also be used to indicate problems such as movementof the end effector 160, base unit 120 and/or robotic arm 140; that workis in progress; that the system 100 is on or off; that the toolpath isrunning or paused; that the system 100 needs attention or refill ofmaterials; and any other indicators of the system state. The userinterface can also display information on the progress, task and toolparameters, and quality metrics of the task being performed.Environmental conditions can also be displayed and recorded by theinterface. The system 100 can indicate to the user what steps to take tocorrect or improve conditions including air quality, temperature andhumidity. If the system 100 detects unsuitable or unsafe conditions, itcan display a message warning the user and providing guidance on nextsteps. The system 100 can use an optimization to find what parameterscould be used to improve the process, including reducing work time,increasing quality, and minimizing material usage among others. The userinterface can also create reports on the tasks executed, qualitymetrics, environmental conditions, completion, and performance logs.Information can include robot workspace, tool paths, progress, sequenceof approach, application rates and thicknesses, spray pressures and flowrates, forces applied by the tool, coverage record, path speed, trackingerror, time to complete the task, tool time, setup time, vacuum wastematerial collected, cleaning time. The user interface can also displayon filter conditions, and the system 100 can trigger an alarm orinstruction when the filter needs to be replaced or cleaned.

The user can interface with the system 100 using a computer, tablet,touch screen, mobile device, pendant, joystick, controller, or buttonsdirectly on the system 100. The worker can also position and train therobotic arm 140 and/or end effector 160 by directly moving joints of therobotic arm 140 or end effector 160. The user interface, controller, orbuttons can be used to record positions as well as change the controlmode and task.

An augmented reality system can be used to show the worker a toolpathplan generated by the system 100, instructions, original BIM or plan, ora combination of these. The augmented reality can be displayed using aheadset, smart goggles, projections, or the like. The worker can beshown areas that require manual coating application. The user can alsooverlay the location of studs, framing, pipes, ducts, and electricalsystems behind the board to facilitate paint application. Paintingtools, both manual and automated, can be tracked in the map using tags,IMUs, or other sensors and a warning can be given to the operator if anattempt is made to apply paint 930 in an erroneous position or under thewrong tool settings. The system 100 or tools can also utilize radar,sonar, thermal imaging, and the like, to establish what is behind thesubstrate.

The automated drywalling system 100 can also produce a visualization,paths, or instructions or a combination of these to guide the user incompleting manual work. The visualization can include 2D or 3D mapsmarking the areas of work with labels. The visualization system can alsoinclude a projection of the plan onto the target surface that can bedone with a laser system, projector, or through augmented realityheadsets or goggles worn by the user.

The coating time, pressure, material flow rate, paint characteristics,and clogs can be tracked to inform when a nozzle 1210 or blade 1130should be cleaned or changed. For example, FIG. 19 illustrates anexample embodiment 160P9 of a painting end effector 160P, whichcomprises a nozzle cassette system 1905 where a cassette of nozzles 1240is attached to the end of the spray gun 1210. The cassette system 1905can be rotated (e.g., via an electromechanical system) to deliver anozzle 1240 to the spray gun 1210 for use.

FIG. 20 illustrates another example embodiment 160P10 of a painting endeffector 160P that comprises of a nozzle rotating system 2005 that canbe part of a spray gun 1210. In this example, the system 100 can utilizean actuator assembly 2010 (e.g., a servo or other electromechanicalactuator) to rotate (e.g., 180 degrees) a portion 2015 of the nozzle1210 allowing for paint 930 to go through the nozzle portion 2015 inreverse helping clear out clogs.

In various embodiments, nozzle or blade wear models can also take as aninput the type and characteristics of paint 930 applied and theconditions under which such paint 930 was applied. One or more visionsystems 364, 324 of the system 100 can be used to detect finish, toolpattern and establish if the nozzle 1240 or blade 1130 needs to bechanged, rotated, cleaned or otherwise modified. A user interface candisplay the wear on the nozzle 1240 or blade 1130 and alert the userwhen these need to be changed. A painting end effector 160P can alsoinclude a mechanism to automatically replace or clean the nozzle 1240 orportions thereof. One embodiment (e.g., FIG. 19 ) can use a cassettewith replacement nozzles 1240 that can be rotated into place. Thesprayer 1210 can also have a mechanism 2005 to rotate the nozzle orportion thereof (e.g. a tip or feeding tube) to clear a clog (e.g., FIG.20 ). The nozzle clearing or replacement can be run automatically by thesystem 100 without any human intervention or as a collaboration betweenthe system 100 and the user.

The system 100 can generate reports and interface with other softwareplatforms including BIM packages. Reports can be created that can beused for inspection and certification. A report can be customized toprovide the information required to pass a standard, test, orcertification. The reporting system can also provide a live update ofthe current task progress and live camera feed. This information can beused to help track asset performance and work progression. The data canbe reported to a BIM system or other software to facilitate planning ofother trades, next steps, or schedule inspections or other tasks. Thereports can include full maps of the paint 930 applied and tool and pathparameters utilized to complete the task. Further images or video can berecorded to facilitate quality checks or for tracking of issues. Thesystem 100 can record parameters used to complete the task which can befed to a machine learning software to enable the system 100 to learnfrom past work. The reports can also be used to optimize workflow andscheduling. The system's optimization function can be updated to meetthe desired needs including minimizing task time, completion of the taskin a part of the worksite to allow other trades to come in, minimizingcost, optimal use of assets and workforce, among others. The system'sreports can also include information on environmental conditions and howthe process was changed given the conditions.

The system 100 can create a report that shows the process parametersthat were used to cover the surface as well as the order of operations.The report can include BIM, 3D and 2D maps or plans, images, and/orvideo. The maps provided by the system 100 can be used to facilitaterepairs and maintenance by providing the customer with the location ofcomponents behind the wall as well as the location of seams tofacilitate the removal of panels or boards.

The updated room models that reflect the as built conditions andmeasurements can be exported for use in sanding the walls or forcertification of quality at delivery. A complete map of the thickness ofthe paint 930 applied with or without shrinking can be fed into thesystem 100 or a separate automated sanding system which can plan toolpaths and parameters desired to achieve the desired finish by sanding.The system 100 can work in conjunction with a larger system that plansthe full process from mapping a room, to cutting and hanging the drywallto finishing and painting of the surfaces. This system 100 can be usedfor coating surfaces with any suitable material, including but notlimited to, joint compound 630, plaster, stucco, cement, paint 930,polymer coating, lacquers, varnishes, or any combination of these. Thesystem 100 can apply the coatings on any suitable substrate, includingbut not limited to, drywall, boards, lath, mesh, or other substrates.The system 100 can also be used to apply other coverings such aswallpaper, polymer films, or the like.

The described embodiments are susceptible to various modifications andalternative forms, and specific examples thereof have been shown by wayof example in the drawings and are herein described in detail. It shouldbe understood, however, that the described embodiments are not to belimited to the particular forms or methods disclosed, but to thecontrary, the present disclosure is to cover all modifications,equivalents, and alternatives.

What is claimed is:
 1. An automated drywalling system for applying paintto drywall of a wall assembly, the automated drywalling systemcomprising: a base unit that includes: a paint source configured tostore paint; a platform, a cart configured to be disposed on and move onthe ground, and a lift disposed between the platform and cart, the liftconfigured to raise the platform up and down; an elongated robotic armthat extends between a base end and a distal end, the robotic armcoupled to the base unit on the platform at the base end of the roboticarm; a painting end effector coupled at the distal end of the roboticarm, the painting end effector including a spray gun configured togenerate a spray of paint from a nozzle of the spray gun, the spray guncoupled with a paint tube extending from the paint source via therobotic arm, the spray gun configured to receive paint from the paintsource via the paint tube to generate the spray of paint; one or morevision systems; one or more sensors; a computing device executing acomputational planner that: obtains target surface data from the one ormore vision systems and the one or more sensors, the target surface dataincluding information regarding a configuration of a wall assemblyincluding a plurality of drywall pieces disposed on the wall assemblyforming one or more joints between respective drywall pieces, the one ormore joints comprising applied joint compound; automatically generates,instructions for driving the painting end effector, robotic arm, andbase unit to perform at least one painting task that includes applying apaint spray generated by the spray gun of the painting end effector toat least the plurality of drywall pieces, the generating based at leastin part on the target surface data; and automatically drives, thepainting end effector, robotic arm, and base unit to perform the atleast one painting task.
 2. The automated drywalling system of claim 1,wherein the generating instructions for driving the painting endeffector, robotic arm, and base unit to apply paint to the one or morejoints between the respective drywall pieces, is further based on dataobtained while the automated drywalling system was sanding the jointcompound disposed on at least the one or more joints between respectivepieces of drywall.
 3. The automated drywalling system of claim 2,wherein the generating instructions for driving the painting endeffector, robotic arm, and base unit to apply paint to the one or morejoints between the respective drywall pieces, is further based on dataobtained while the automated drywalling system was applying jointcompound to the one or more joints between respective pieces of drywall.4. The automated drywalling system of claim 1, wherein the painting endeffector further comprises a UV light used to accelerate curing of paintapplied to the drywall pieces.
 5. The automated drywalling system ofclaim 1, wherein the painting end effector further comprises a vacuumhood disposed around an end and the nozzle of the spray gun to captureoverspray generated by the spray of paint generated by the nozzle of thespray gun.
 6. The automated drywalling system of claim 1, wherein thepainting end effector further comprises a blower, wherein the firstblower is configured to apply dry air to paint that has been applied bythe painting end effector.
 7. An automated drywalling system comprising:a base unit; an elongated robotic arm that extends between a base endand a distal end, the robotic arm coupled to the base unit at the baseend of the robotic arm; a painting end effector coupled at the distalend of the robotic arm, the painting end effector configured to applypaint to a target surface; one or more vision systems; and a computingdevice executing a computational planner that: obtains target surfacedata from the one or more vision systems, the target surface dataincluding information regarding a configuration of a wall assemblyincluding a plurality of drywall pieces disposed on the wall assembly;automatically generates instructions for driving the painting endeffector, robotic arm, and base unit to perform at least one paintingtask that includes applying paint, via the painting the end effector, toat least the plurality of drywall pieces, the generating based at leastin part on the target surface data; and automatically drives the endeffector, robotic arm, and base unit to perform the at least onepainting task.
 8. The automated drywalling system of claim 7, whereinthe painting end effector applies paint to a target surface via at leastone of a spray gun and a roller.
 9. The automated drywalling system ofclaim 7, wherein the painting end effector further comprises a blower,wherein the blower is configured to apply dry air to paint that has beenapplied by the painting end effector.
 10. The automated drywallingsystem of claim 7, wherein the painting end effector comprises a sprayguard that at least partially extends about and past a nozzle of a spraygun of the painting end effector.
 11. The automated drywalling system ofclaim 7, wherein the generating instructions for driving the paintingend effector, robotic arm, and base unit to apply paint to the pluralityof drywall pieces, is further based on data obtained while the automateddrywalling system was sanding joint compound disposed on one or morejoints between respective pieces of the plurality of drywall pieces. 12.The automated drywalling system of claim 7, wherein the generatinginstructions for driving the painting end effector, robotic arm, andbase unit to apply paint to the plurality of drywall pieces, is furtherbased on data obtained while the automated drywalling system wasapplying joint compound to one or more joints between respective piecesof drywall.
 13. The automated drywalling system of claim 7, wherein thepainting end effector further comprises a vacuum hood disposed around anend of a spray gun to capture overspray generated by a spray of paintgenerated by the spray gun.
 14. An automated coating system comprising:a positioning stage that extends between a base end and a distal end; acoating end effector coupled at the distal end of the positioning stage,the coating end effector configured to apply a coating to a targetsurface; and a computing device executing a computational planner that:generates instructions for driving the coating end effector andpositioning stage to perform at least one coating task that includesapplying a coating, via the coating the end effector, to a plurality ofdrywall pieces, the generating based at least in part on obtained targetsurface data; and drives the end effector and positioning stage toperform the at least one coating task.
 15. The automated coating systemof claim 14, wherein the computational planner obtains at least aportion of the target surface data from one or more vision systems, thetarget surface data including information regarding a configuration ofthe plurality of drywall pieces.
 16. The automated painting system ofclaim 14, wherein the coating comprises at least one of a paint,adhesive, varnish, film, or polymer coating.
 17. The automated paintingsystem of claim 14, wherein the coating end effector further includes aguiding element configured to engage the target surface or adjacentportion of a wall assembly to guide the coating end effector in coatingthe target surface.
 18. The automated coating system of claim 14,wherein the generating instructions for driving the coating end effectorand positioning stage to apply coating to the plurality of drywallpieces, is further based on data obtained while the automated drywallingsystem was sanding joint compound disposed on one or more joints betweenrespective pieces of the plurality of drywall pieces.
 19. The automatedcoating system of claim 14, wherein the positioning stage comprises arobotic arm.
 20. The automated painting system of claim 14, wherein thepainting end effector further comprises a vacuum hood disposed around anend of a spray gun of the painting end effector to capture overspraygenerated by a spray of paint generated by the spray gun.